Insulated cementaceous building block system and blocks

ABSTRACT

A concrete building block for masonry block walls is formed with first, second and third spaced rectangular face shells, where the second face shell is intermediate the first and third face shells. First and second cross webs connect the first and second face shells and a third cross web connects the second and third face shells. Insulating cores include end protrusions extending outwardly at the top edge thereof to fit into notches of the cross webs and include cutouts to accommodate mortar crumbs. The insulating cores further mate, creating an overlap that serves to (i) insulate against temperature transfer and (ii) provide a sound barrier. A unique block permits a combination of insulating inserts and solid grouting as well as a symmetric arrangement.

CROSS-REFERENCE

This application is a continuation-in-part of U.S. patent applicationSer. No. 16/776,388 filed on Jan. 29, 2020 which is incorporated hereinfor all purposes.

FIELD OF THE INVENTION

The embodiments of the present invention relate to an improved insulatedcementitious building block system and blocks.

BACKGROUND

Building blocks made of concrete or cementitious material are widelyused for building structures. Typically, these blocks are laid inrunning courses with horizontal and vertical mortar joints, known asbutt joints and head joints, to construct a wall. The mortar bonds theblock material together to form the completed wall construction.Conventional cement block wall construction employs blocks which areclosed at the ends by cross webs, and which typically include a singlecross web substantially at the midpoint of the block. The open spacesbetween the cross webs are used to provide air spaces for insulationpurposes and to reduce the weight of the block. These open spaces alsoare used to accommodate reinforcing bar placement and grout cells forproviding a structurally reinforced wall.

Efforts have been made to improve the insulation qualities of concreteblock walls by filling the voids between the supporting cross webs withmolded insulating material during manufacture of the block. When suchcells are prefilled, however, and the block is stored in an outdoorstorage yard pending shipment, the insulating material frequentlydeteriorates in reaction to ultraviolet rays and the like. In addition,when the hollow cells in a masonry block are pre-filled at manufacture,the block is difficult to handle, because of an inadequate means ofpicking up the block. The foam fills the cores preventing a mason fromefficiently grasping the central web or the end web of the block andplacing it, a process that is repeated for each and every block duringconstruction. Masons generally prefer a block which can be handled withone hand so that the other hand can be free to hold a trowel, some othertool, or carry another block.

It is desirable to provide an improved insulated masonry building blockwhich overcomes the disadvantages of the prior art, and which employsgenerally conventional masonry techniques in wall construction using theblock coupled with effective insulation and ease of handling.

SUMMARY

The embodiments of the present invention broadly comprise an insulatedmasonry building block system including masonry blocks constructed withfirst, second and third spaced parallel rectangular face shells,commonly referred to as face shells within the industry, in which thesecond face shell is intermediate the first and third face shells. Firstand second vertical end cross webs connect the first and second faceshells and each of the first and second end cross webs have a notch inthem extending a predetermined distance from the top toward the bottom.First and second spaced intermediate vertical cross webs then arelocated on planes between the planes of the first and second end webs toconnect the second and third face shells, leaving open cavities at theends of the second and third face shells. Each of these intermediatecross webs also have a notch therein extending from the top apredetermined distance toward the bottom.

The insulated masonry building block system further includes a firstinsulating core dimensioned to substantially fill the space between thefirst and second face shells and the first and second end cross webswith end protrusions extending outwardly near the top thereof to fitinto the notches in the first and second end cross webs. The firstinsulating core includes top and bottom edges, with end protrusionsextending outwardly at the top edge thereof to fit into notches of crosswebs of said masonry building blocks, said end protrusions havingcutouts in bottoms thereof to accommodate mortar crumbs; and alongitudinal notch along the entire bottom edge and a longitudinal notchalong the entire top edge wherein said longitudinal notch along saidbottom edge is dimensioned to fit into a longitudinal notch along a topedge of a neighboring one of said insulating cores creating an overlapthat serves to (i) insulate against temperature transfer and (ii)provide a sound barrier.

The insulated masonry building block system may further include a secondinsulating core dimensioned substantially to fill the space between thefirst and second spaced intermediate cross webs with end protrusionsextending outwardly at the top edge thereof to fit into the notches insaid first and second spaced intermediate cross webs, said endprotrusions having cutouts in bottoms thereof to accommodate mortarcrumbs; and a longitudinal notch along the entire bottom edge and alongitudinal notch along the entire top edge wherein said longitudinalnotch along said bottom edge is dimensioned to fit into a longitudinalnotch along a top edge of a neighboring one of said second insulatingcores creating an overlap that serves to (i) insulate againsttemperature transfer and (ii) provide a sound barrier.

Another embodiment of the present invention comprises a block designconfigured for solid grouting in combination with insulating inserts.

Other variations, embodiments and features of the present invention willbecome evident from the following detailed description, drawings andclaims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a partially exploded perspective view of a firstembodiment of the present invention;

FIG. 2 illustrates a top view of a portion of the first embodiment shownin FIG. 1 according to the embodiments of the present invention;

FIG. 3 illustrates a cross-sectional view taken along the line 3-3 ofFIG. 2 according to the embodiments of the present invention;

FIG. 4 illustrates a cross-sectional view taken along the line 4-4 ofFIG. 2 according to the embodiments of the present invention;

FIG. 5 illustrates an end view taken along the line 5-5 of FIG. 2according to the embodiments of the present invention;

FIG. 6 illustrates a cross-sectional view taken along the line 6-6 ofFIG. 2 according to the embodiments of the present invention;

FIG. 7 illustrates a cross-sectional view taken along the line 7-7 ofFIG. 2 according to the embodiments of the present invention;

FIGS. 8A and 8B illustrate alternative constructions of the firstembodiment shown in FIGS. 1 and 2 according to the embodiments of thepresent invention;

FIG. 9 illustrates front perspective view illustrating additionalfeatures of the first embodiment shown in FIGS. 1 and 2 according to theembodiments of the present invention;

FIG. 10 illustrates an end view of a portion of one embodiment of thepresent invention constructed into a wall according to the embodimentsof the present invention;

FIG. 11 illustrates a cross-sectional view of a portion of oneembodiment of the present invention showing specific features thereofaccording to the embodiments of the present invention;

FIGS. 12A and 12B illustrate a perspective end view and top down view ofa block of the type used with the embodiments of the present invention;

FIGS. 13A and 13B illustrate second embodiment first inserts accordingto the embodiments of the present invention;

FIGS. 14A and 14B illustrate third embodiment first inserts according tothe embodiments of the present invention;

FIGS. 15A and 15B illustrate the third embodiment first inserts stackedaccording to the embodiments of the present invention;

FIGS. 16A and 16B illustrate second embodiment second inserts stackedaccording to the embodiments of the present invention;

FIGS. 17A and 17B illustrate a third embodiment first insert and secondembodiment insert positioned within a building block according to theembodiments of the present invention;

FIG. 17C illustrates multiple third embodiment first inserts positionedwithin a pair of building blocks according to the embodiments of thepresent invention;

FIGS. 18A and 18B illustrate third embodiment first inserts and secondembodiment second inserts interacting with sounds waves according to theembodiments of the present invention;

FIG. 19 illustrates a perspective upper view of a second embodiment of ablock according to the embodiments of the present invention;

FIG. 20 illustrates a top down view of the second embodiment of theblock according to the embodiments of the present invention;

FIG. 21 illustrates an end view of the second embodiment of the blockwith design criteria according to the embodiments of the presentinvention;

FIG. 22 illustrates a top down view of the second embodiment of theblock with design criteria according to the embodiments of the presentinvention;

FIGS. 23A and 23B illustrate cross-sectional views of the secondembodiment of the block according to the embodiments of the presentinvention;

FIGS. 24A and 24B illustrate an upper perspective view of the secondembodiment of the block with insulation inserts and a wall formedthereof according to the embodiments of the present invention; and

FIG. 25 illustrates a cross-sectional view of the second embodiment ofthe block with a reinforcement bar in place according to the embodimentsof the present invention.

DETAILED DESCRIPTION

For the purposes of promoting an understanding of the principles inaccordance with the embodiments of the present invention, reference willnow be made to the embodiments illustrated in the drawings and specificlanguage will be used to describe the same. It will nevertheless beunderstood that no limitation of the scope of the invention is therebyintended. Any alterations and further modifications of the inventivefeature illustrated herein, and any additional applications of theprinciples of the invention as illustrated herein, which would normallyoccur to one skilled in the relevant art and having possession of thisdisclosure, are to be considered within the scope of the inventionclaimed.

Reference now should be made to the drawings, in which the samereference numbers are used throughout the different figures to designatethe same components. FIG. 1 is an exploded front perspective view of apreferred embodiment of the invention. As shown in FIG. 1, a concrete orcementitious building block 10 is constructed of three primary parallelface shells, 11, 18 and 20. The face shells are of equal length and havea top surface located in a first horizontal plane and a bottom surfacelocated in a second horizontal plane. The block 10 has externaldimensions which are selected to be comparable to the standarddimensions of concrete building blocks throughout the constructionindustry.

The opposite ends of the face shells 11 and 18 are joined together toform a closed compartment by first and second vertical end cross webs 15and 17. These cross webs 15 and 17 have U-shaped notches 14 and 16located in them extending a short distance from the top of the crosswebs toward the bottoms thereof This is shown most clearly in FIGS. 1, 5and 6.

As shown most clearly in FIG. 2, intermediate cross webs 21 and 23,located in parallel planes spaced between the planes of the cross webs15 and 17, are used to join the face shells 18 and 20 together. Theseintermediate cross webs also have notches 22 and 24, respectively,located in them, again as shown most clearly in FIGS. 2, 5 and 6.

The resulting structure of the block is illustrated in its various partsin FIGS. 2 through 7. From an examination of FIG. 2, it is apparent thata cavity 12 is located between the face shells 11 and 18 and the endcross webs 15 and 17. Another cavity 13 is formed between the faceshells 18 and 20 and the cross webs 21 and 23. All of the face shells11, 18 and 20 and the cross webs 15, 17, 21 and 23 have a uniformthickness or cross section from the top of the block to the bottom toprovide the maximum volume for the cavities which are formed betweenthem.

The center face shell 18 is designed with an ergonomically designedhandle formed by a void or U-shaped hollow area located approximately 2½inches from the top of the face shell 18. This is shown most clearly inFIG. 7. The area over the top of this void 19 a comfortable, easy togrip handle for manipulating the block 10 during the construction of awall. This void of material also serves to lighten the total weight ofan individual block without compromising its structural integrity. Thebottom of this handle area, which is parallel to the top of the faceshell 18, also may be molded with curved or rounded edges todramatically decrease wear and abrasion on the fingers or gloves of aworkman installing these blocks in a wall.

In constructing a wall with the blocks shown in FIGS. 1 through 7,standard mortar masonry practices are used to align and plumb the walls.The blocks are set in place in courses, utilizing the same techniqueswhich are employed for standard cement building blocks in the industry.After a course of blocks has been laid, the foam inserts 30 and 40 whichare shown in the exploded view of FIG. 1 are fit into the appropriatecell cavities. The elongated enclosed cell cavities 12 in each of theindividual blocks are filled with an insulated core foam insert 30, asshown in FIG. 1. This foam insert is designed to be snug fitting in thecavity 12, but to further facilitate its insertion, ribs 36 are formedon one of the surfaces so that if there is an anomaly in the interiorsurfaces of the face shells 11 or 18, these ribs easily are shaved downby the naturally abrasive cementitious material while being inserted toprovide a quick and simple fit of the insulating core in the cavity 12.To hold the core 30 in place, there are outwardly projecting protrusionsor ears 32 and 34, on opposite sides, located near its upper surface.These projections 32 and 34 fit into the U-shaped notches 14 and 16 inthe vertical end cross webs 15 and 17 to hold the insulating core 30 inplace. The core 30 has a top to bottom dimension selected to cause it tobe located within the cavity 12 in such a manner that it does not extendabove the upper edge or upper surface of the face shells 11, 18 and 20.

It readily can be seen that when a series of the blocks 10 are laid in acourse in a conventional manner, the head joints on the sides are mortarfilled, as are the bottom butt joints. It is well known that standardmortar masonry practices frequently result in some excess mortar seepagealong the bottom of the cavity 12 and along the edges spilling into theopen-ended cavities located on the right and left-hand sides of theintermediate cross webs 21 and 23, shown in FIG. 2. To prevent a breakin the mechanical bond which is provided by this mortar and to avoiddisturbing the mortar, the insulation core 30 is undercut along itsedges at 38, as shown in FIG. 1. Thus, the bottom of the insulating core30 is stepped back from the face shells 11 and 18 so that nointerference with the mortar seepage on the butt joints occurs. Thebottom of the core 30, between the undercut portions, extends below theface shells 18 and 20 into the space created by the mortar in the buttjoints. A second set of shorter inserts 40 then is provided to fit intothe cavity 13 between the face shells 18 and 20 and the intermediatecross webs 21 and 23, again as illustrated in FIG. 1. The core inserts40 also have vertical ribs 46 on them to accommodate any anomalies whichmay be present in the cavity 13 to permit easy insertion of the coreinserts 40 into the cavity, as shown in FIG. 1. In addition, the centerof each of the core inserts 40 has a vertical notch or groove 47extending from the top to the bottom to space the insert 40 from theinterior of the face shell 20. As with the core inserts 30, the inserts40 also have projecting ears or tabs 42 and 44, on opposite sides, forresting in the notches 22 and 24, respectively, of the block 10. As withthe core inserts 30, the inserts 40 are placed in the blocks in themanner shown in FIG. 1 after a course of blocks has been laid.

As is apparent from an examination of FIG. 1, the core inserts 40 notonly are placed in the region 13 between the webs 21 and 22 of anindividual block, but also bridge the space between these cross webs andthe mating cross webs of the adjacent block in the manner shown inFIG. 1. When this is done, the center vertical groove 47 is located inthe region of the head joints between the blocks to accommodate anymortar seepage which takes place in this area. This avoids disturbingthe mortar at the head joints. As with the core inserts 30, the coreinserts 40 also include an undercut or notch 48 at the bottom toaccommodate mortar seepage along the butt joints at the bottoms of theblocks and the inserts 40 extend slightly below the bottom plane of theblocks. As a consequence, no break in the mechanical bond is occasionedby insertion of the insulating cores 30 and 40 in the manner shown inFIG. 1 after a course of blocks has been laid. This unique and precisedesign of the foam inserts does not interfere with the mortar (wet ordry) excess areas when the inserts are placed into appropriate cellcavities in the blocks.

FIG. 10 is a partially cut-away end view of the portion 15 of the blockshown in FIGS. 1 and 2 illustrating the orientation of a pair of blocks15 in vertically adjacent courses, and showing the orientation of theinsulating core insert 30 when the blocks 15 are mortar set, one uponthe other. The mortar has not been shown in FIG. 10 in order to clarifythe drawing. As is illustrated in FIG. 10, the protrusion 32 fits intothe U-shaped notch 14 to allow the upper surface of the core insert 30to be co-planar with the top of the block. The bottom or lower edge ofthe core 30 rests on the top of the corresponding core 30 in the nextlower course of blocks 15. The longitudinal undercut notches 38 on eachside of the core 30 provide a space for mortar seepage, as is readilyapparent from an examination of FIG. 10.

FIG. 11 is a cross-sectional view of a portion of the spaced-apart walls18 and 20 of the block shown in FIGS. 1 and 2 illustrating theorientation and location of insulating cores 40 when these cores are inplace in blocks of immediately adjacent upper and lower courses ofblocks installed into a wall by means of a conventional mortarconstruction. An identical orientation and location of the insulatingcores 30 also exists as shown in FIG. 10. As shown in FIG. 11, thenotches 48 extend from the lower plane of the walls 18 and 20 of theupper block to the lower edge or bottom surface of the core 40 by adistance equal to the finished thickness and seepage of a mortar joint60, as illustrated. The top edge or upper surface of the core 40 islocated in the same plane as the top edges of the walls 18 and 20 of theblock. The notches 48 extend longitudinally along the entire bottom edgeof both sides of the cores 40, as illustrated in FIG. 11.

Since the wall thicknesses of the face shells 11, 18 and 20 and the wallthickness of the cross webs 15, 17, 21 and 23 are uniform from top tobottom (or have a slight taper from top to bottom for manufacturingpurposes), a maximum volume of the cavities in the block is provided.This permits the thicknesses of the insulating core inserts 30 and 40 tobe uniform (or nearly uniform) from top to bottom to permit a maximumfilling of insulating material into the blocks during the constructionof a wall.

As desired, various ones of the cells in the blocks may be filled withrebar and grout installation, in accordance with standard concrete blockinstallation practices. It also is a simple matter to provide horizontalrebar in various courses of a wall by laying the rebar in the notches14, 16 or 22, 24 and applying grout as necessary. Obviously, when thisis done, those particular blocks are not provided with the insulatingcores 30 and 40.

An additional improvement may be provided in the middle face shell 18 inthe form of precision vertical scoring at each end of the handle formedby the undercut or void area 19. This permits a mason to lightly tap thehandle with a hammer to easily remove the handle in the event that avertical rebar protruding from either footings, stem walls or lower bondbeams interferes with the handle.

As illustrated in FIG. 9, a significant advantage of the three faceshell construction of the block is in the manner in which electrical boxplacements can be effected within the masonry wall. Standard orconventional cement masonry blocks have two deep (approximately 5″) cellcavities, one on each side of a middle cross web. Typically, a masoncuts the block face where an electrical box is specified in the wall.Standard, readily available electrical box configurations areconsiderably less deep than the depth of these standard cavities. A,mason has no efficient method of securing an electrical box flush withthe inside face of the block. There is no apparatus currently available,short of time consuming and costly masonry screws, to secure electricalboxes in place during construction when standard masonry blocks areused.

In the block which is shown in FIGS. 1 through 7 and 9, however,electrical box placement is greatly facilitated. The placement procedureidentically begins with the mason cutting the block face to form arectangular cutout 50, as shown in FIG. 9. A standard, readilyavailable, universally manufactured electrical box 58/56 then is placedin the cutout, simply by sliding it into the cavity from the top to restin place in the cutout box opening. The rear of the box 50 rests againstthe handle area of the center face shell 18 to precisely hold it inplace. Again, the open cells allow for standard, readily available,universally manufactured and approved electrical conduit chases, bothvertical 60 and horizontal 62 to be used without the requirement ofactually installing any wiring. The conduits can be placed in the blocksin the manner shown and extend through various courses and fromblock-to-block within a course in the same manner as discussedpreviously for the installation of rebar. As a consequence, the blockconstruction greatly facilitates subsequent electrical wiring of abuilding using the structures which have been shown.

FIGS. 8A and 8B show variations of the top view of the block shown inFIGS. 1 and 2 which may be used as corner or in-line pilaster blocks,which alternatively can be stacked in a running bond to provide a largergrout cell, as may be required by structural engineering. These cells 70and 80 duplicate regular concrete block cell dimensions, and, therefore,structural capability, as well as serving as a corner block to provide afinished corner, since the block shown in FIGS. 1 through 7 has opencavities on its ends and is not satisfactory for corner construction.

FIG. 12 illustrates an upper perspective view of a block 100 used with asecond embodiment of the present invention. The block 100, like theblock 10 in FIG. 1, includes a first face shell 110, second face shell120, third face shell 130, first vertical end cross web 140, secondvertical end cross web 150, first intermediate vertical cross web 160and second intermediate vertical cross web 170. The first and secondvertical end cross webs 140, 150 connect the first and second faceshells 110, 120 and each of the first and second end cross webs 140, 150have a notch 145, 155 therein extending a predetermined sloping distancefrom the top toward the bottom. The first and second spaced intermediatevertical cross webs 160, 170 are located on planes between the planes ofthe first and second end cross webs 140, 150 connecting the second andthird face shells 120, 130. Each of these intermediate vertical crosswebs 160, 170 also has a notch 165, 175 therein extending from the top apredetermined sloping distance toward the bottom.

During the normal building block manufacturing process, some excess ofthe aggregate cement mixture from which the building blocks 100 arefabricated inadvertently falls into the notches 145, 155, 165 and 175 ofthe building blocks 100. This unwanted aggregate debris, termed “crumbs”180 herein becomes a nuisance to the mason during the installation ofthe insulating cores 30, 40 (shown in FIG. 1) because the pre-formedears 32, 34 are routinely inhibited from full insertion into the cores30, 40 by the “crumbs” 180.

Now referring to FIGS. 13A and 13B, first embodiment insulating core(aka inserts) 200 is dimensioned to substantially fill the space betweenthe first and second face shells 110, 120 and the first and second endcross webs 130, 140. This insulating core 200 is also deemed a shortinsert. The core 200 has end protrusions 210-1, 210-2 extendingoutwardly from both sides near the top thereof to fit into the notches145, 155 in the first and second end cross webs 140, 150. The endprotrusions 210-1, 210-2 include cut-outs 235-1, 235-2 proximate thebottom thereof to accommodate the crumbs and prevent unwantedinterference with the installation of the first insulating core 200.Vertically running ribs 215-1 through 215-N accommodate any anomalieswhich may be present in the cavity of a building block to permit easyinsertion of the core inserts 200 into the cavity. FIG. 17A shows aninsulating core 200, having the cut-out 235, in position forinstallation into the block 100.

The first insulating core 200 also has a pair of longitudinal notches240-1, 240-2 along the bottom thereof and a longitudinal notch 230 alongthe top thereof. Longitudinal notch 240-2 is dimensioned to mate withthe top longitudinal notch 230 of a neighboring insulating core as shownin FIGS. 15A and 15B.

FIGS. 14A and 14B show second embodiment insulating core 300 similar tosaid first embodiment insulating core 200 having end protrusions 310-1,310-2, cut-outs 335-1, 335-2, a pair of longitudinal notches 340-1,340-2 along the bottom thereof and a longitudinal notch 330 along thetop thereof. The second embodiment insulating core 300 also includes aseries of vertically running channels 305-1 through 305-N on a firstside and vertically running ribs 315-1 through 315-N on a second side.The vertically running ribs 315-1 through 315-N accommodate anyanomalies which may be present in the cavity of a building block topermit easy insertion of the core inserts 300 into the cavity. As shownbest in FIG. 18A, the vertically running channels 305-1 through 305-Nserve to break up sound waves as described in more detail below.

Now referring to FIGS. 15A and 15B, longitudinal notch 340-2 in core300-1 extends below a mortar joint and into the longitudinal notches330-2, 330-3 of cores 300-2, 300-3 respectively. In this manner, thecores 300 are configured to stack such that no gap exists between thebottom of an upper core and the top of a lower core. Indeed, the matingoverlap created by the lower longitudinal notches and the upperlongitudinal notches serves to insulate against temperature transfer andprovide a more efficient sound barrier.

Cores 200, 300 may include a vertical groove 333 extending from the topto the bottom thereof at substantially the midpoint. The vertical groove333 is located in the region of the head joints between the blocks toaccommodate any mortar seepage which takes place in the area.

Now referring to FIGS. 16A and 16B, second insulating cores 400-1through 400-3 are shown in a stacked arrangement. Cores 400-1 through400-3 are dimensioned substantially to fill the space between the firstand second spaced intermediate vertical cross webs 160, 170. The secondinsulating cores (aka inserts) 400-1 through 400-3 have end protrusions410-1 through 410-3 and 420-1 through 420-3 extending outwardly from thetop thereof on each side to fit into the notches 165, 175 in theintermediate vertical cross webs 160, 170. These insulating cores 400-1through 400-3 are also deemed long inserts. The second insulating cores400-1 through 400-3 have a length sufficient to allow a single core toindividually fill the space between vertical cross webs 160, 170. Theend protrusions 410-1 through 410-3 and 420-1 through 420-3 includemortar-accommodating cut-outs 415-1 through 415-3 and 425-1 through425-3, respectively.

The insulating cores 400-1 through 400-3 have first longitudinal notches430-1 through 430-3 and second longitudinal notches 440-1 through 440-3along the bottom thereof and longitudinal notches 450-1 through 450-3along the top thereof. Longitudinal notches 325-1, 325-2 are dimensionedto mate with the longitudinal notches 330-1, 330-2 of neighboringinsulating cores 300-1, 300-2 as shown in FIGS. 14A and 14B.

FIGS. 16A and 16B show core 400-1 above cores 400-2, 400-3 such thatlongitudinal notch 440-1 extends below a mortar joint and into notches450-2, 450-3 in the top of core 400-2, 400-3, respectively. In thismanner, the cores 400 are configured to stack such that no gap existsbetween the bottom of the top core 400-1 and the top of the bottom cores400-2, 400-3. Indeed, the mating overlap created by the lowerlongitudinal notches and the upper longitudinal notches serves toinsulate against temperature transfer and provide a more efficient soundbarrier.

FIGS. 17A and 17B illustrate a third embodiment first insert 300 andsecond embodiment insert 400 positioned within a building block 15according to the embodiments of the present invention. As best shown inFIG. 17A, the cut-outs 335-2, 425-2 accommodate crumbs 180 of the typeshown in FIG. 12A. FIG. 17A also shows notches 340, 440 extending belowa bottom of the building block 15 for mating with upper notches ofneighboring inserts.

FIG. 17C illustrates multiple third embodiment first inserts 300-4through 300-N positioned within a pair of building blocks 20, 25according to the embodiments of the present invention.

FIGS. 18A and 18B illustrate third embodiment first inserts 300 andsecond embodiment second insert 400 interacting with sounds wavesaccording to the embodiments of the present invention. As the soundswaves 360, 410 contact the inserts 300, 400 the sound waves disseminateupwards (arrow A) and downwards (arrow B) along channels 305-1 through305-N and channels 405-1 through 405-N, respectively. By re-directingthe sound waves, less sound is able to penetrate the building block andinserts and exit into the protected area.

In one embodiment, the inserts have a height of 7.87″ or 0.13″ (⅛″)short of 8″ which equals the sum of the a 7.625″ tall building block andthe 0.375″ thick butt mortar joint. This height permits the inserts tooverlap as detailed above. Those skilled in the art will recognize thatother building blocks may require the dimensions of the inserts to bemodified.

FIGS. 19-25 show a second embodiment of block 500 according to theembodiments of the present invention. The block 500 is ideal forsingle-wythe walls which can be solid-grouted thus preventing moisturefrom wicking through the wall. As used herein, solid-grouted walls meanthe core portions with reinforcement are grouted. That is, one spacedsection is filled with inserts 501 and the other spaced section isfilled with reinforcement bars 503 and grout.

As best shown in FIGS. 20, 21 and 23, the block 500 is H-shapedcomprising three spaced face shells 502, 504 and 506. Cross webs 508,510 extend between face shells 502 and 504 while cross web 512 extendsbetween face shells 504 and 506. Cross webs 508, 510 each include aU-shaped notch 512, 514 to accommodate insulating inserts. Face shells504, 506 have angled inner surfaces 505, 507 providing for variablethicknesses along their lengths. The face shells 502, 504, as designed,provide additional space to accommodate grout. In one embodiment, theblock 500 is fabricated of concrete using a single mold.

As designed, the block 500 permits a symmetric arrangement wherebyreinforcement bars are able to be positioned in a center of thestructural foundation of the block 500. As shown in FIG. 25, thestructural foundation of the block 500 is shown by arrow A. In oneembodiment, the structural foundation of the block 500 is the portion ofthe block 500 defined by face shells 504, 506 or about 8″ of an 8″ block500. Accordingly, the reinforcement bars 503 may be positioned about 4″from the outer surface of face shell 502 and inner surface of face shell504 as best shown in FIGS. 24B and 25. This is a symmetric arrangementthat provides the most efficient and structurally sound wall. Inpractice, once the reinforcement bars 503 are positioned, grout is usedto fill in the spaces between face shells 502, 504.

In practice the block 500 may be used to form a wall as shown in FIG.24A with inserts 501 positioned between face shells 502 and 504 andsolid grout between face shells 504 and 506. As detailed above, thereinforcement bars 503 are able to be centered within the structuralfoundation of the block 500.

Although the invention has been described in detail with reference toseveral embodiments, additional variations and modifications existwithin the scope and spirit of the invention as described and defined inthe following claims.

I claim:
 1. An insulated masonry building block system for use in amortar set masonry wall comprising: blocks having: first, second andthird spaced, rectangular face shells, with said second face shelllocated intermediate said first and third face shells, wherein saidfirst, second and third rectangular face shells each have a bottom edgelocated in a first horizontal plane and said first, second and thirdrectangular face shells each have a top edge located in a secondhorizontal plane; first and second cross webs connecting said first andsecond face shells in first and second respective planes, each of saidfirst and second cross webs having a notch therein extending apredetermined distance from the top thereof toward the bottom thereof; athird cross web connecting said second and third face shells, said thirdcross web having a notch therein extending from the top thereof apredetermined distance toward the bottom thereof; one or more insulatingcores dimensioned to substantially fill space between said first andsecond face shells and said first and second end cross webs, said one ormore insulating cores having top and bottom edges, with end protrusionsextending outwardly at the top edge thereof to fit into the notches insaid first and second end cross webs, said end protrusions havingcutouts in bottoms thereof to accommodate mortar crumbs, said one ormore insulating cores having a longitudinal notch along the entirebottom edge and a longitudinal notch along the entire top edge whereinsaid longitudinal notch along the entire bottom edge is dimensioned tofit into a top longitudinal notch of a neighboring one of said one ormore insulating cores; and wherein space between said second face shelland said third face shell is dimensioned to receive one or morereinforcement bars and grout whereby said reinforcement bars arepositioned approximate to a center of a structural foundation of saidblock.
 2. The insulated masonry building block system of claim 1 whereinsaid longitudinal notch along the entire bottom edge fitting into saidtop longitudinal notch of a neighboring one of said one or moreinsulating cores creates an overlap that serves to (i) insulate againsttemperature transfer and (ii) provide a sound barrier.
 3. The insulatedmasonry building block system according to claim 1 wherein said thirdcross web is positioned about one-half the length of said second andthird face shells.
 4. The insulated masonry building block systemaccording to claim 1 wherein said first, second and third rectangularface shells, said first, second and third cross webs are formed fromconcrete.
 5. The insulated masonry building block system according toclaim 1 wherein said notches in said first, second and third cross webshave a generally U-shaped configuration.
 6. An insulated masonrybuilding block system for use in a mortar set masonry wall comprising:blocks having: first, second and third spaced, rectangular face shells,with said second face shell located intermediate said first and thirdface shells, wherein said first, second and third rectangular faceshells each have a bottom edge located in a first horizontal plane andsaid first, second and third rectangular face shells each have a topedge located in a second horizontal plane; first and second cross websconnecting said first and second face shells in first and secondrespective planes, each of said first and second cross webs having anotch therein extending a predetermined distance from the top thereoftoward the bottom thereof; a third cross web connecting said second andthird face shells, said third cross web having a notch therein extendingfrom the top thereof a predetermined distance toward the bottom thereof,inner surfaces of said second and third face shells angled as said innersurfaces extend from said third cross web; one or more insulating coresdimensioned to substantially fill space between said first and secondface shells and said first and second end cross webs, said one or moreinsulating cores having top and bottom edges, with end protrusionsextending outwardly at the top edge thereof to fit into the notches insaid first and second end cross webs, said end protrusions havingcutouts in bottoms thereof to accommodate mortar crumbs, said one ormore insulating cores having a longitudinal notch along the entirebottom edge and a longitudinal notch along the entire top edge whereinsaid longitudinal notch along the entire bottom edge is dimensioned tofit into a top longitudinal notch of a neighboring one of said one ormore insulating cores; and wherein space between said second face shelland said third face shell is dimensioned to receive one or morereinforcement bars and grout whereby said reinforcement bars arepositioned approximate to a center of a structural foundation of saidblock.
 7. The insulated masonry building block system of claim 6 whereinsaid longitudinal notch along the entire bottom edge fitting into saidtop longitudinal notch of a neighboring one of said one or moreinsulating cores creates an overlap that serves to (i) insulate againsttemperature transfer and (ii) provide a sound barrier.
 8. The insulatedmasonry building block system according to claim 6 wherein said thirdcross web is positioned about one-half the length of said second andthird face shells.
 9. The insulated masonry building block systemaccording to claim 6 wherein said first, second and third rectangularface shells, said first, second and third cross webs are formed fromconcrete.
 10. The insulated masonry building block system according toclaim 6 wherein said notches in said first, second and third cross webshave a generally U-shaped configuration.
 11. The insulated masonrybuilding block system according to claim 6 wherein said inner surfacesof said second and third face shells are angled such that a distancebetween said inner surfaces of said second and third face shellsincreases away from said third cross web.
 12. A masonry blockcomprising: first, second and third spaced, rectangular face shells,with said second face shell located intermediate said first and thirdface shells, wherein said first, second and third rectangular faceshells each have a bottom edge located in a first horizontal plane andsaid first, second and third rectangular face shells each have a topedge located in a second horizontal plane; first and second cross websconnecting said first and second face shells in first and secondrespective planes, each of said first and second cross webs having anotch therein extending a predetermined distance from the top thereoftoward the bottom thereof; a third cross web connecting said second andthird face shells, said third cross web having a notch therein extendingfrom the top thereof a predetermined distance toward the bottom thereof,inner surfaces of said second and third face shells angled as said innersurfaces extend from said third cross web; and wherein space betweensaid second face shell and said third face shell is dimensioned toreceive one or more reinforcement bars and grout whereby saidreinforcement bars are positioned approximate to a center of astructural foundation of said block.
 13. The block of claim 13 whereinsaid bock has a width of about 12″ and said second and third face shellsare about 8″ in width.
 14. The block of claim 13 wherein a space betweensaid first and second face shell and said first and second end crosswebs are configured to receive one or more insulating cores having topand bottom edges, with end protrusions extending outwardly at the topedge thereof to fit into the notches in said first and second end crosswebs, said end protrusions having cutouts in bottoms thereof toaccommodate mortar crumbs, said one or more insulating cores having alongitudinal notch along the entire bottom edge and a longitudinal notchalong the entire top edge wherein said longitudinal notch along theentire bottom edge is dimensioned to fit into a top longitudinal notchof a neighboring one of said one or more insulating cores.
 15. The blockof claim 14 wherein said longitudinal notch along the entire bottom edgefitting into said top longitudinal notch of a neighboring one of saidone or more insulating cores creates an overlap that serves to (i)insulate against temperature transfer and (ii) provide a sound barrier.16. The block of claim 12 wherein said third cross web is positionedabout one-half the length of said second and third face shells.
 17. Theblock of claim 12 wherein said first, second and third rectangular faceshells, said first, second and third cross webs are formed fromconcrete.
 18. The block of claim 12 wherein said notches in said first,second and third cross webs have a generally U-shaped configuration.